scholarly journals Amelioration of Capacity Constraints in Manufacturing Systems Using Alternate Production Sequence

2017 ◽  
Vol 5 (1) ◽  
pp. 73-92
Author(s):  
Dhagash Shah ◽  
Krishna Krishnan ◽  
Mukund Dhuttargaon
Keyword(s):  
Production System ◽  
Manufacturing Systems ◽  
Material Handling ◽  
Facility Layout ◽  
Production Capacity ◽  
Capacity Constraints ◽  
Product Mix ◽  
Product Demand ◽  
Demand Changes ◽  
The Cost

Today’s market is in a constant flux of demand changes.  Due to this the product demand and the product mix continuously change from one time-period to the next.  For a company to be profitable and competitive, it has to ensure that all of its resources are optimally utilized.  These resources include facility layout, material handling, and production system.  Previous research has shown that the system state has to be identified prior to increasing capacity to mitigate the constraint.  As the demand and product mix change, a facility layout that was efficient can soon become inefficient or the cost of production and material handling increase.  This research evaluates usage of alternate part sequence as a means to eliminate or reduce production system constraints.  It focuses on reducing machine usage when the selected process sequence leads to production capacity constraints.

PERBAIKAN TATA LETAK LANTAI PRODUKSI INDUSTRI MEBEL MENGGUNAKAN METODE GRAFIK DAN ALGORITMA CRAFT

2020 ◽  
Vol 6 (1) ◽  
pp. 1
Author(s):  
Kuswanto Kuswanto ◽  
Juan Junius ◽  
Anita Christine Sembiring
Keyword(s):  
Operating System ◽  
Material Handling ◽  
Facility Layout ◽  
Integrated Planning ◽  
Furniture Manufacturing ◽  
Milling Machines ◽  
Material Handling Costs ◽  
The Cost ◽  
A Company ◽  
Research Show

Facility layout is integrated planning of the flow of a product in an operating system to obtain the most effective and efficient interrelation between workers, materials, machinery, and equipment as well as handling and transferring materials. A company engaged in furniture manufacturing has a problem in its production process, namely, the distance between machines is too far so that it affects the cost of handling materials. Distant workstations are found on profile machines, milling machines, measuring machines, cutting machines. Therefore, improvements must be made to the layout of facilities on the production floor so that facility layout is efficient and material handling costs are reduced. The problem-solving approach used is the Graph Method and CRAFT Algorithm. The results of the research show that material handling costs are reduced by 7.58% or Rp. 17,765 using the CRAFT algorithm.

Optimisation of Facility Layout Problem at Automotive Industry a Case Study in Sabah

2013 ◽  
Vol 315 ◽  
pp. 755-761 ◽  
Author(s):  
Kah Song Tan ◽  
Noor Ajian Mohd-Lair ◽  
Stephen Yong Nai-Vun ◽  
James Yong Chau-Leong
Keyword(s):  
Material Handling ◽  
Facility Layout ◽  
Production Capacity ◽  
Layout Problem ◽  
Throughput Time ◽  
Facility Layout Problem ◽  
Manufacturing Line ◽  
Handling Cost ◽  
Material Handling Cost ◽  
Arena Simulation

The general Facility Layout Problem deals with the arrangement of machines within the facility based on the constraints such as material flow distance, volume of flow of products, material handling cost and operation sequence of product. The facility layout problem is directly linked with the efficiency of the facility or the manufacturing line. The objective of this project is to design a simulation based methodology experiment on designing an optimized facility layout and evaluating the proposed alternative layouts using ARENA simulation. This project is conducted at Benteng Motor Sdn. Bhd. in Kota Kinabalu, Sabah. Currently, the company is planning to expand their manufacturing plant and hence the company needs an optimized facility layout to maximize the product capacity and manufacturing throughput time on a minimum utilization of resources environment. An eight steps simulation methodology is being proposed to design an optimized facility layout. A manufacturing re-engineering scenario has been developed to improve the existing system. The proposed scenario was evaluated using Arena simulation student package. The scenario has significantly increases the production capacity up to 225%, decrease the manufacturing throughput time by 19% as well as increase the utilization of majority of the manufacturing resources more than 200%.

Automation in Manufacturing Operation of Crankshaft

2013 ◽  
Author(s):  
Nand K. Jha
Keyword(s):  
Production System ◽  
High Speed ◽  
Manufacturing Systems ◽  
Depth Of Cut ◽  
Optimum Process ◽  
Design Data ◽  
Decomposition Approach ◽  
Automated Production ◽  
Multistage Manufacturing ◽  
The Cost

This paper deals with multistage flow type manufacturing of crankshafts. The advanced methodologies in manufacturing systems, re-configurability and high speed manufacturing adopted in the paper will help reduce cost and improve productivity. The optimization of the multistage manufacturing is based on mathematical programming formulation and decomposition approach. The optimum process parameters such as speed, feed and depth of cut for individual operations are calculated using this technique. The effect of change in design data on manufacturing parameters and eventually the cost of the crankshaft at each operation are visualized. This is likely to help the manufacturing engineers to attempt to reduce cost at appropriate stage. The manufacturing automation of crankshaft is attempted on the methodology presented in the paper. The final configuration of the automated production system shows the specification of machine tools in the production system.

scholarly journals Scalability analysis of selected structures of a reconfigurable manufacturing system taking into account a reduction in machine tools reliability

2021 ◽  
Vol 23 (2) ◽  
pp. 242-252
Author(s):  
Arkadiusz Gola ◽  
Zbigniew Pastuszak ◽  
Marcin Relich ◽  
Łukasz Sobaszek ◽  
Eryk Szwarc
Keyword(s):  
Manufacturing Process ◽  
Machine Tools ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Production Capacity ◽  
Cost Effective ◽  
Simulation Software ◽  
Reconfigurable Manufacturing ◽  
Product Demand ◽  
The Impact

Scalability is a key feature of reconfigurable manufacturing systems (RMS). It enables fast and cost-effective adaptation of their structure to sudden changes in product demand. In principle, it allows to adjust a system's production capacity to match the existing orders. However, scalability can also act as a "safety buffer" to ensure a required minimum level of productivity, even when there is a decline in the reliability of the machines that are part of the machine tool subsystem of a manufacturing system. In this article, we analysed selected functional structures of an RMS under design to see whether they could be expanded should the reliability of machine tools decrease making it impossible to achieve a defined level of productivity. We also investigated the impact of the expansion of the system on its reliability. To identify bottlenecks in the manufacturing process, we ran computer simulations in which the course of the manufacturing process was modelled and simulated for 2-, 3-, 4- and 5-stage RMS structures using Tecnomatix Plant Simulation software.

Increasing the Efficiency of Robotic Manufacturing Systems by Layout Optimization

2015 ◽  
Vol 762 ◽  
pp. 283-290
Author(s):  
Bogdan Mocan ◽  
Darius Buna ◽  
Mircea Fulea ◽  
Stelian Brad
Keyword(s):  
Material Flow ◽  
Manufacturing Systems ◽  
Material Handling ◽  
High Efficiency ◽  
Facility Layout ◽  
Flow Path ◽  
Decision Matrix ◽  
Analytic Hierarchy ◽  
Volume Flexibility ◽  
Multi Criteria Evaluation

To achieve high efficiency in a robotic manufacturing system, an optimized layout arrangement and material flow path design are important due to the large percentage of product cost that is related to material handling, equipment positioning, material flow path, and products variety and volume (flexibility). Facility layout problem (FLP) can be considered as a multi-criteria problem due to presence of the qualitative criteria such as flexibility and the quantitative criteria for instance total cost of handling material. In this paper, we combined a well-known facility layout algorithm (CRAFT) with Analytic Hierarchy Process (AHP) technique and decision matrix method to facilitate a multi criteria evaluation. The proposed approach aims to incorporate qualitative criteria in addition to quantitative criteria for evaluating facility layout patterns. A case study on a robotic system for manufacturing plate type oil coolers reveals the effectiveness of the proposed approach.

Holistic simulation-based optimisation methodology for facility layout design with consideration to production and logistics constraints

2021 ◽  
pp. 095440542110173
Author(s):  
Enrique Ruiz Zúñiga ◽  
Erik Flores García ◽  
Matías Urenda Moris ◽  
Masood Fathi ◽  
Anna Syberfeldt
Keyword(s):  
Material Handling ◽  
Facility Layout ◽  
Holistic Approach ◽  
Multiple Attribute Decision Making ◽  
Layout Design ◽  
Analytic Hierarchy ◽  
Facility Layout Design ◽  
Multiple Attribute ◽  
Simulation Based ◽  
Optimisation Methods

Facility layout design is becoming more challenging as manufacturing moves from traditionally emphasised mass production to mass customisation. The increasing demand for customised products and services is driving the need to increase flexibility and adaptability of both production processes and their material handling systems. A holistic approach for designing facility layouts with optimised flows considering production and logistics systems constraints seems to be missing in the literature. Several tools, including traditional methods, analytic hierarchy process, multiple-attribute decision making, simulation, and optimisation methods, can support such a process. Among these, simulation-based optimisation is the most promising. This paper aims to develop a facility layout design methodology supported by simulation-based optimisation while considering both production and logistics constraints. A literature review of facility layout design with simulation and optimisation and the theoretical and empirical challenges are presented. The integration of simulation-based optimisation in the proposed methodology serves to overcome the identified challenges, providing managers and stakeholders with a decision support system that handles the complex task of facility layout design.

A New Procedure of Production Orders Sequencing in Mixed-Model Production Systems

2014 ◽  
Vol 1036 ◽  
pp. 864-868 ◽  
Author(s):  
Marcin Zemczak ◽  
Damian Krenczyk
Keyword(s):  
Task Scheduling ◽  
Production System ◽  
Mixed Model ◽  
Production Systems ◽  
Production Capacity ◽  
Approximate Solutions ◽  
Task Sequence ◽  
Optimal Method ◽  
Sequencing Problem ◽  
Car Sequencing

The paper presents the task scheduling issue, which main aim is to establish a proper sequence of tasks, that would maximize the utilization of companys production capacity. According to the literature sources, the presented sequencing problem, denoted as CSP (Car Sequencing Problem) belongs to the NP-hard class, as has been proven by simple reduction from Hamiltonians Path problem. Optimal method of solution has not yet been found, only approximate solutions have been offered, especially from the range of evolutionary algorithms. Regardless of specific production system, while considering reception of new tasks into the system, current review of the state of the system is required in order to decide whether and when a new order can be accepted for execution. In this paper, the problem of task scheduling is limited to the specific existing mixed-model production system. The main goal is to determine the effective method of creation of task sequence. Through the use of computational algorithms, and automatic analysis of the resulting sequence, rates of production are able to be checked in a real time, and so improvements can be proposed and implemented.

An Unequal-Sized Unidirectional Loop Layout Design Problem Considering Empty Vehicle Trip

2010 ◽  
Vol 37-38 ◽  
pp. 116-121
Author(s):  
Yu Lan Li ◽  
Bo Li ◽  
Su Jun Luo
Keyword(s):  
Material Handling ◽  
Design Principle ◽  
Facility Layout ◽  
Original Model ◽  
Layout Problem ◽  
Proposed Model ◽  
Loop Layout ◽  
Material Handling Costs ◽  
Loop Layout Problem ◽  
Better Than

In the facility layout decisions, the previous general design principle is to minimize material handling costs, and the objective of these old models only considers the costs of loaded trip, without regard to empty vehicle trip costs, which do not meet the actual demand. In this paper, the unequal-sized unidirectional loop layout problem is analyzed, and the model of facility layout is improved. The objective of the new model is to minimize the total loaded and empty vehicle trip costs. To solve this model, a heuristic algorithm based on partheno-genetic algorithms is designed. Finally, an unequal-sized unidirectional loop layout problem including 12 devices is simulated. Comparison shows that the result obtained using the proposed model is 20.4% better than that obtained using the original model.

MINIMUM AVERAGE COST PRODUCTION PLANNING IN STOCHASTIC MANUFACTURING SYSTEMS

1998 ◽  
Vol 08 (07) ◽  
pp. 1251-1276 ◽  
Author(s):  
SURESH P. SETHI ◽  
HANQIN ZHANG ◽  
QING ZHANG
Keyword(s):  
Control Problem ◽  
Production Planning ◽  
Average Cost ◽  
Production Cost ◽  
Manufacturing Systems ◽  
Production Control ◽  
Production Capacity ◽  
Production Rates ◽  
Planning Problems

Recently, the production control problem in stochastic manufacturing systems has generated a great deal of interest. The goal is to obtain production rates to minimize total expected surplus and production cost. This paper reviews the research devoted to minimum average cost production planning problems in stochastic manufacturing systems. Manufacturing systems involve a single or parallel failure-prone machines producing a number of different products, random production capacity, and constant demands.

PRACTICAL PRODUCTION LAYOUT DESIGN FOR MULTI-PRODUCT AND SMALL-LOT-SIZE PRODUCTION: A CASE STUDY

2016 ◽  
Vol 78 (7) ◽  
Author(s):  
Cheng Ying, Nyeoh ◽  
Hasnida Ab-Samat ◽  
Shahrul Kamaruddin
Keyword(s):  
Manufacturing Systems ◽  
Production Efficiency ◽  
Job Shop ◽  
Flow Line ◽  
Facility Layout ◽  
Layout Design ◽  
Simulation Software ◽  
Utilization Rate ◽  
Lot Size ◽  
Related Data

Facility layout design has an important function in manufacturing systems because it affects manufacturing costs, work in progress, lead times, and production output. This study presents facility layout designs for multi-product and small-lot-sized production lines. This research focuses on the development and analysis of layout alternatives on the basis of performance measures and aims to improve production efficiency. Thus, the tools and techniques available for the layout designed were investigated. Related data were collected, and alternative layouts were developed using the WITNESS simulation software. Finally, the alternative layouts were ana1yzed and evaluated using the analytic hierarchy process to identify the best possible layout. Two important parameters observed in the alternative layouts: the ability to produce a desired output and the flexibility of each layout coherent with the fluctuation of product demands in the industry. Results from analysis shows that suggested Model 3 with the combination of flow line and job shop configurations is the most suitable layout. This model has the highest machine utilization rate and the highest labour utilization rate yet requires only 21 operators, the lowest number of workers. For future work, this type of layout should be tested with different variation in lot sizes.

Sign in / Sign up

Export Citation Format

Share Document